Critical Design Review Wind Turbine with Gearbox Team G: Nick Koerner (Lead), Meteb Almutairi, Chris Batsch, Mike Villamar

Project Objectives The Main Goal is Control The Arduino Mega Microcontroller will serve as the control center of the wind turbine. Items that are being controlled by the microcontroller: Transistor Switching E-Brake Voltage Monitor Physical Hydraulic Brake Controlled by Servo Frequency Detection Simple Voltage regulator being used to protect microcontroller Efficiency and Power Output High Efficiency is desired Switching Regulator 5V, 2A, and 10W of Power

Modes of Operation Generation Mode Shutdown Mode The E-brake switch will be open, and voltage monitor switch will be closed. This allows for the generator to spin freely, and the battery bank to connect to the generator. Shutdown Mode The E-Brake switch will be closed, and the voltage monitor switch will be open. The generator will be shorted: Slows down the generator and dumps energy into the dump load. The hydraulic brake will be activated by the servo, and cause the wind turbine to come to a complete stop. Generation will be reactivated after a delay, or battery bank needs charging, or manual override.

Functional Decomposition

Full Circuit Schematic

Subassemblies Battery Bank Sub Specs: Batteries Lithium Ion Battery 2800mAh Battery Bank provides 9 V, 2.16 A Capacitor 1000 uF Generator Sub Specs: Bridge Rectifier RS402L MAX: 100 V, 4 A IGBT ISL9V3040P3 MAX: 430 V, 17 A Power Resistor 50W Generator ElectriFly Ammo Frequency Detection Voltage Protection 1N4742 Zener Diode Max: 12 V, 1 W

Subassemblies Brake Sub Specs: Turnigy Digital Metal Gear Servo 6 V Input Torque: 17 kg/cm Load Sub Specs: Step Down Switching Regulator (2 Options) L4978 IC Requires 8 V to 55 V input Produces 5 V and 2 A output ~90% Efficient Simple and all values given NR887D IC Requires 4.5 V to 18 V input Not all values given, further testing once obtained Voltage Monitor (R6 & R7) Simple Voltage Divider for 5 V Analog Pin

Construction Plan Structural Hardware: Previous components Used: Much of the structural hardware used in the previous wind turbine project will be recycled in this current design, therefore the plan is to build on top of that. Previous components Used: The Blades, Shaft, Gearbox, Generator, and Hydraulic Brake will be reused. Battery Bank Brackets and metal tabs will be used to connect the batteries in the correct setup. The new components that are chosen will fit on the aluminum platform (shown on next slide). What does not fit, will rest a platform on the ground.

Additional Fabrication Plans Proto-Boards The current plan is to use the EECS shop provided vector proto-boards to place the circuits upon. The Goal To make custom PCB circuit boards using the EECS shop’s PCB milling machine. Depending on the time, and Eagle CAD training, the task can be completed before the deadline.

Testing DC Motor for in Lab Wind Simulations Wind Tunnel for Final Testing The Max Wind Speed Tested is 34 MPH Tests the Generation and Shutdown Modes >40 MPH Shutdown Feature Can or will be Adjusted Input/Output Efficiency

In Lab Wind Simulation Data from Testing Wind Speed [MPH] Voltage [V] RPM of Generator [RPM] Frequency [Hz] 11.18 1.79 1005.82 16.76 22.37 3.46 2012.53 33.54 33.55 4.50 3018.35 50.31

Schedule Task Projected Completion Proposal 2/4/2015 DC Motor for Wind Simulation 2/13/2015 Preliminary Research 2/20/2015 Analyze Wind Turbine Design PDR Detailed Overview Research 3/13/2015 Circuit Schematic CDR 4/1/2015 Order Parts 4/3/2015 Programming Microcontroller 4/17/2015 Construction Wind Tunnel Testing 4/24/2015 Project Completion 5/6/2015

Org Chart

Challenges/Risks Programming Components Scheduling Testing Batteries Programming the microcontroller will take some time and research. Scheduling Meeting times due to different schedules of everyone in group is a conflict. Batteries Potential risk of explosion and or fire. Components Size, rating, and cost must be considered for durability and because structure from last year is being used. Testing Availability of wind tunnel and making sure wind simulation matches actual wind tunnel performance.

Questions?